I Know What You're Thinking...

[flatisflat]

Why didn't MINI ever offer the ALL4 setup in the 2nd gen MINI Cooper Clubman (R55)? I know, right?! The sheer ludicrousness of this omission boggles the mind. Luckily for you, I'm beginning to look into the remedy for this shortcoming.

This here is the first installment of ....not a build thread... because I have nowhere near the cashflow for such an undertaking, but I figured I'd start depositing the results of my internet sleuthing on the matter.

Section 1. What are you ranting about again?

While the generations get funny if you think about it too hard, the R60 Countryman was BMW-MINI's first foray into offering all-wheel drive and is a part of the same 2nd generation as my R55 Clubman. Given how the Clubman is just a MINI Cooper plus nine inches in length, I began to wonder in just how many ways a Countryman might just be a taller, slightly more girthy Clubman.

The All4 system is manifested via the utilization of a GKN electromagnetic clutch pack (EMCD) assembled just fore of a rear differential.

(Fig. 2) EMCD:

These, paired with a transfer case (or power-take-off) developed by Getrag, are the core of the mechanical changes to implement the 'All4' system in the Countryman.

Transfer Case (though this photo is actually minutely inaccurate which had led to some misleading conclusions previously):

_

Section 2. I Can Already Tell You're Leaving Stuff Out

Well....yeah...obvs?
The thing I started looking into first was trying to figure out what all is a direct transfer between the two vehicles.

Engines:
Identical. The part numbers that I've come across thus far seem to get a little wonky, but in short, the turbocharged 1.6L I4's (N18B16A) which is had in the mid-cycle refreshed 2nd-gen S variant MINI's are all the same. And by comparing photos of a non-All4 N18 engine with the below, I believe I've confirmed both engine casings have the identical threaded bosses to accept this passenger-side mounting bracket (black part) for the PTO:

Transmissions:
The same! Same gear ratios, same final drive, same same! Well...except for some stuff...

For a non-All4 MINI, the lack of the transfer case (pink) means the passenger-side CV assembles directly to the differential output from the transmission. And while it may not be immediately obvious (such as it wasn't to me for daaaaays), the transfer case really changes the requirements for this area.
In short, the 'Hollow Shaft' has female splines to mate with that outer splined shaft (which is also hollow) coming from the differential, while that 'Link Shaft' separately provides a direct link from the differential to the shortened All4-specific front passenger CV. And what, pray tell, might you notice in the Clubman non-All4 transmission below?

No male splined output from the transmission/diff. Oh yeah, and no mounting points for the transfer case. Minor details...
In short, I belieeeeeeeve the 'passenger-side' of the transmission is a unique casting to facilitate creating the mounting bosses for the transfer case, and for allowing the necessary space so that male-splined shaft can be housed for the (now two) passenger-side shafts exiting the transmission. Everything else thus being equal with the non-All4 manual transmission. I think...
_

Alright, that's it for Part 1!
Next up, I'll be covering more of the front end such as the subframes, exhaust routing, and front suspension.

[pip bip]

but "electronics"

[flatisflat]

@pip-bip You mean Part 5 where I start theorizing about all the ways I can dodge fussing around with near any of that nonsense?

[pip bip]

@flatisflat thats' the one

[Exage03040]

Oh I know how this goes...

It's a good write-up though, will be interesting.

[іди на хуй Влад - formerly known as Distraxi]

This sort of obsessive attention to the fine details of something totally pointless is what makes Oppo great. My hat is raised to you, sir.

[SilentbutnotreallyDeadly]

@flatisflat you are well down the road that many VW T4 van owners have been on...thinking they can easily convert their FWD van to AWD by using 'a couple of parts' from a T4 van with the factory syncro transmission.

It's so not that simple that I recall reading about one bloke collecting three dead T4 syncro vans from all over Europe and doing the conversion to his own van...even after he'd realised it would have been easier and cheaper just to buy a working T4 syncro. Which is the Oppo way when it's all said and done.

[flatisflat]

@silentbutnotreallydeadly Yup, I don't doubt that the deeper I go, the worse off this whole situation will get. Unfortunately, I like the 2nd gen. Clubman so much more than the Countryman that just buying an All4 Countryman simply isn't in the brain cards.

[dieseldub]

@flatisflat looks a lot like Haldex AWD, which VAG and others use for their transverse mount AWD systems.

Always good to have an OE setup you can get parts for to do such a swap. Who knows, maybe you'll come across a wrecked All4 for cheap and be able to scavenge the parts to make it happen!